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The performance of stainless steel (SS) powder metallurgy (P/M) materials in automotive exhaust system applications continues to be a subject of interest. Reported within are results of several investigations into the properties of several P/M stainless steel alloys at elevated temperatures. Elevated temperature tensile testing was conducted to determine the strength of P/M alloys at exhaust system operating conditions. Cyclical elevated temperature corrosion/oxidation/quench testing was also conducted to determine corrosion/oxidation performance of various alloys in exhaust system environments. Both 300 and 400 series alloys, as well as some specially modified and specially processed alloys, were subjected to the above tests. Various processing parameters were used to illustrate the dramatic effects of processing on material performance. Recommendations are provided for alloy selection and alloy properties in exhaust system applications.

In this presentation, the development of a camshaft sprocket for a V8 engine application will be reviewed. P/M camshaft sprockets have been used in automobile engines for a number of years. Recent requirements - weight and noise reduction, increasing horse power and wear characteristics have increased the demands on P/M in terms of materials and processing. Incorporating both a sprocket and spur gear in one design, varying wall thicknesses, achieving uniform densities, and minimizing distortion in heat treatment presented quite a challenge.

Aluminum powder metallurgy (P/M) has been the subject of renewed attention recently. This is driven by the need to reduce weight, improve efficiency (such as fuel economy), and reduce costs. A review of the materials available, how they are processed, and how they perform, as compared to wrought and cast forms, will provide a current status in aluminum P/M technology. Some insight will be given into the direction of future technology.

The performance of stainless steel(SS) powder metallurgy (P/M) materials in elevated temperature applications has become a subject of interest with P/M now being considered for automotive exhaust type applications. This study will outline the results of an investigation into the properties of several P/M stainless steel materials at elevated temperatures and relate these P/M materials to ingot metallurgy counterparts. Recommendations on the manufacturing of stainless steel P/M exhaust system components will also be presented.